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DESIGNING WITH
PLASTI CS AN D
COMPOSITES:
A HANDBOOK
Donald V. Rosato, Ph. D.
David P. Di Mattia
Industrial and Graphic Designer
Dominick V. Rosato
P.E. Rhode Island School of Design
~
SPRINGER SCiENCE+BUSINESS MEDIA, LLC
Copyright © 1991 by Springer Science+Business Media New York
Originally published by Van Nostrand Reinhold in 1991
Softcover reprint of the hardcover 1s t edition 1991
Library of Congress Catalog Number 90-46378
ISBN 978-1-4615-9725-4 ISBN 978-1-4615-9723-0 (eBook)
DOl 10.1007/978-1-4615-9723-0
All rights reserved. No part of this work covered by
the copyright hereon may be reproduced or used in any
form by any means-graphic, electronic, or
mechanical, including photocopying, recording, taping,
or information storage and retrieval systems-without
written permission of the publisher.
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2
Library of Congress Cataloging-in-Publication Data
Rosato, Donald V.
Designing with plastics and composites: a handbook
by Donald V. Rosato, David P. Di Mattia, and Dominick V. Rosato.
p. cm.
Includes bibliographical references and index.
1. Plastics. 2. Engineering design. I. Di Mattia, David P.
II. Rosato, Dominick V. III. Title.
TP1122.R67 1991
668.4'9--dc20 90-46378
CIP
Contents
Preface / ix
1. FUNDAMENTALS OF DESIGNING WITH PLASTICS AND
COMPOSITES / 1
Design Shape / 49
Success by Design / 51
Computers in Design / 52
Design Procedure / 54
Interrelating Product-Resin-Process Performances / 55
2. THE STRUCTURE AND BASIC PROPERTIES OF PLASTICS / 61
Plastic Structures and Morphology / 66
Thermal Properties of Plastics / 83
Thermal Conductivity and Thermal Insulation / 87
Heat Capacity / 88
Thermal Diffusivity / 88
The Coefficient of Linear Thermal Expansion / 89
Deflection Temperature Under Load / 94
Decomposition Temperature / 95
Mechanical Properties / 96
Physical Properties / 98
Rheology and Deformation / 107
Interrelating Properties, Plastics,and Processing / 116
Orientation / 11 8
Shrinkage / 123
3. PLASTICS: DESIGN CRITERIA / 125
Mechanical Properties / 133
Short-Term Behavior / 135
Long-Term Behavior / 153
Short-Duration Rapid and Impact Loads / 201
Electrical Properties / 223
Friction, Wear, and Hardness Properties / 239
iii
iv CONTENTS
4. ENVIRONMENTAL CONDITIONS AFFECTING PLASTICS / 253
Temperature Introduction / 253
Chemical Resistance / 264
Weather Resistance / 272
Sterilization-Irradiation / 274
Permeability and Barrier Resistance 276
Biological and Microbial Degradation / 281
Flammability / 282
The Ocean Environment / 288
The Space Environment / 297
5. STRUCTURAL DESIGN ANALYSIS / 303
Load-Bearing Products / 303
Loads / 305
Support Conditions / 305
Simplifications and Assumptions / 308
Multiaxial Stresses and Mohr's Circle / 308
Safety Factors / 309
Beam Bending Stresses / 312
Beam Bending and Spring Stresses / 321
Shear Stress and Torsion / 323
Shear Stress and Direct Shear / 325
Pressure Vessels / 325
Externally Loaded RP Pipe / 326
Molded-In Inserts / 340
Press Fits / 342
Snap Fits / 345
Hinges / 349
Thread Strength / 355
Pipe Threads / 358
Gears / 359
Gaskets and Seals / 360
Grommets and Noise / 360
Impact Loads / 361
Thermal Stresses / 362
Structural Foams / 365
Structural Sandwiches / 368
Energy and Motion Control / 371
Failure Analysis / 387
Dimensional Tolerances / 387
Plastics / 388
Processing and Tolerances / 391
Product Specification / 398
Combining Variables / 399
Finite Element Analysis / 399
Cantilevered Snap Fits / 402
Laws and Regulations / 402
CONTENTS v
6. THE PROPERTIES OF PLASTICS / 405
Trade Names / 405
Acrylonitrile-Butadiene-Styrene (ABS) / 406
Acetal / 414
Acrylics / 415
Alkyds / 416
Aminos / 416
Cellulosics / 417
Chlorinated Polyethers / 417
Chlorinated Polyethylene / 418
Cross-Linked Polyethylene (XLPE) / 418
Diallyl Phthalate / 418
Epoxies / 419
Ethylene-Vinyl Acetates 419
Fluoroplastics / 420
Furan / 421
lonomers / 421
Ketones / 422
Liquid Crystal Polymers / 422
Melamines / 423
Nylons (Polyamides) / 423
Parylenes / 425
Phenolics / 426
Phenoxy Resins / 427
Polyallomers / 428
Polyamides / 428
Polyamide-imide / 428
Polyarylates / 430
Polyarylethers / 430
Polyaryletherketone / 430
Polyarylsulfone / 431
Polybenzimidazole / 431
Polybutylenes / 432
Polybutylene Terephthalate / 432
Polycarbonates / 432
Polyesters / 433
Polyetherketone / 436
Polyetheretherketone / 438
Polyetherimide / 439
Polyethersulfone / 440
Polyethylene / 440
Polyethylene Terephthalate / 445
Polyimides / 445
Polymethyl Methacrylate / 445
Polymethylpentene / 446
Polyolefins / 446
Polyphenylene Ether / 446
Polyphenylene Sulfide / 447
vi CONTENTS
Polypropylene / 447
Polystyrene / 449
Polysulfones / 449
Polyurethane / 452
Polyvinyl Chloride / 452
Polyvinylidene Fluoride / 455
Silicones / 455
Urea Formaldehydes / 456
Elastomers / 458
Thermoset Elastomers / 467
Thermoplastic Elastomers / 472
Film and Sheeting / 473
Foams / 475
Transparent and Optical Plastics / 491
Reinforced Plastics and Composites / 493
Regrind and Recycling / 524
Guide for Plastics Identification / 525
Computerized Databases / 528
Selection Worksheets / 535
Selecting Materials / 535
Selecting Materials under Dynamic Loading / 540
7. THE PROCESSING OF PLASTICS / 589
Tolerances and Shrinkages / 596
Model Building / 596
Molds and Dies / 599
Drying Hygroscopic Plastics / 602
Heat History, Residence Time, and Recycling / 602
Process Control / 603
Troubleshooting / 603
Inspection / 606
Injection Molding / 610
Extrusion / 624
Basics of Flow / 630
In-Line Postforming / 641
Blow Molding / 646
Extrusion Blow Molding / 651
Forming / 665
Reinforced Plastics/Composites 670
Other Processes / 687
Selecting Processing / 695
8. AUXILIARY EQUIPMENT AND SECONDARY OPERATIONS / 711
Material Handling / 713
Parts Handling / 713
Finishing and Decorating / 714
Joining and Assembling / 714
Machining / 727
CONTENTS vii
9. TESTING AND QUALITY CONTROL / 731
Basics versus Complex Tests / 732
Specifications and Standards / 732
Orientation and Weld Lines / 734
Types of Tests / 735
Thermoanalytical Tests / 735
Nondestructive Testing / 746
Computer Testing / 753
Quality Auditing / 753
Reliability and Quality Control / 754
Failure Analysis / 754
Selecting Tests / 755
Quality and Control / 755
10. COMPUTER-AIDED DESIGN / 757
Mold Design / 758
CAD/CAM Modeling / 763
Additional CAD/CAM Features Used in Plastic Part and Mold Design / 773
Process-Analysis Tools / 777
Design Databases / 782
Computer-Integrated Manufacturing / 785
Myths and Facts / 785
Capability and Training / 786
11. DESIGN FEATURES THAT INFLUENCE PERFORMANCE / 789
Basic Detractors and Constraints / 789
Injection Molding / 796
Extrusion / 844
Blow Molding / 847
Thermoforming / 854
Reinforced Plastics and Composites / 856
Rotational Molding / 865
Assembly Methods / 869
Mechanical Loading / 870
12. CONCLUSIONS / 877
Product Diversification / 879
Materials Diversification / 883
Equipment Improvements / 887
The Solid-Waste Problem and Product-Design Solutions / 889
Technical Cost Modeling / 898
Success by Design / 900
Design Considerations / 900
Challenge Requires Creativity / 914
The Future / 915
viii CONTENTS
Appendix A. General Information Sources / 919
Appendix B. Conversions / 921
Appendix C. Trade Names / 925
Appendix D. Computerized Software and Databases / 929
References / 937
Index / 967
